Bi-metallic drill bit mandrel utilizing precipitation hardened material pre-joined to a drill bit mandrel suitable for infiltration
Aspects of the subject technology relate to tools, system and methods related to a drilling tool that is fabricated using a bimetallic member that is subjected to an infiltration process. The method can include having an amount of precipitation hardenable steel and an amount of another type of steel. The precipitation hardenable steel and the other type of steel are metallurgically bonded to form a bimetallic member including a casting mandrel portion and a drill string connection portion. A reinforcing powder is infiltrated with a binder while in contact with the casting mandrel portion to form a metal matrix composite about the casting mandrel portion. A cutting structure is fabricated into the metal matrix composite of the drilling tool.
1 . A method of manufacturing a drilling tool for a downhole drill string comprising:
having an amount of precipitation hardenable steel;
having an amount of steel, distinct from the precipitation hardenable steel;
metallurgically bonding the amount of precipitation hardenable steel to the amount of steel, thereby forming a bimetallic member comprising a casting mandrel portion and a drill string connection portion;
infiltrating a reinforcing powder with a binder in contact with the casting mandrel portion of the bimetallic member to form a metal matrix composite about the casting mandrel portion, after the amount of precipitation hardenable steel is metallurgically bonded to the amount of steel; and
fabricating a cutting structure in the metal matrix composite.
2 . The method of claim 1 , further comprising forming a threaded connection in the drill string connection portion of the bimetallic member for attaching the drilling tool to a downhole drill string.
3 . The method of claim 1 , wherein the bimetallic member is formed without welding any additional material to the bimetallic member after infiltrating the reinforcing powder with the binder.
4 . The method of claim 1 , further comprising performing a post-infiltration heat treatment process.
5 . The method of claim 1 , wherein the amount of precipitation hardenable steel and the amount of steel are metallurgically bonded together before the infiltration step using friction welding, electron beam welding, laser welding, diffusion bonding, or a combination thereof.
6 . The method of claim 1 , wherein the metallurgical bonding comprises using fusion with a filler material and is performed before the infiltration step.
7 . The method of claim 1 , wherein the steel is a low-carbon steel and comprises a carbon content between 0.03% and 0.6% by weight.
8 . The method of claim 1 , wherein the amount of precipitation hardenable steel comprises a minimum achievable yield strength of 100 ksi.
9 . The method of claim 1 , wherein the amount of precipitation hardenable steel comprises a Nickel alloy.
10 . The method of claim 1 , wherein the amount of precipitation hardenable steel and the amount of steel are bonded together to form the bimetallic member without using a V-weld groove or an alignment thread region about a bonding interface between the amount of precipitation hardenable steel and the amount of steel.
11 . The method of claim 1 , wherein a bonding interface between the amount of precipitation hardenable steel and the amount of steel to form the bimetallic member is a substantially fully bonded cross-section.
12 . The method of claim 1 , wherein a bonding interface between the amount of precipitation hardenable steel and the amount of steel to form the bimetallic member is in proximity to a blank bond line where the metal matrix composite is attached to the casting mandrel portion of the bimetallic member.
13 . A drilling tool for a downhole drill string comprising:
a casting mandrel portion comprising an amount of steel;
a drill string connection portion comprising an amount of precipitation hardenable steel, wherein the amount of steel is distinct from the amount of precipitation hardenable steel;
a cutting structure fabricated in a metal matrix composite formed about the casting mandrel portion, wherein the metal matrix composite comprises a reinforcing powder infiltrated with a binder in contact with the casting mandrel portion; and
a bimetallic member comprising the amount of steel and the amount of precipitation hardenable steel metallurgically bonded together before the reinforcing powder is infiltrated with the binder.
14 . The drilling tool of claim 13 , wherein the steel is a low-carbon steel and comprises a carbon content between 0.03% and 0.6% by weight.
15 . The drilling tool of claim 13 , wherein the amount of precipitation hardenable steel has a minimum achievable yield strength of 100 ksi.
16 . The drilling tool of claim 13 , wherein the amount of precipitation hardenable steel comprises a Nickel alloy.
17 . The drilling tool of claim 13 , wherein the drill string connection portion is treated through a post infiltration heat treatment.
18 . The drilling tool of claim 13 , wherein the bimetallic member further comprises a bonding interface between the amount of precipitation hardenable steel and the amount of steel, and further wherein the bonding interface has a substantially fully bonded cross-section.
19 . The drilling tool of claim 13 , wherein the bimetallic member further comprises a bonding interface between the amount of precipitation hardenable steel and the amount of steel, wherein the bonding interface is located proximate to a circumferential blank bond line where the metal matrix composite is attached to the casting mandrel portion of the bimetallic member.
20 . The drilling tool of claim 13 , further comprising a bonding interface between the amount of the precipitation hardenable steel and the amount of the steel and the bonding interface is formed without a filler material.
21 . The drilling tool of claim 20 , wherein the bonding interface comprises a minimum achievable yield strength of 100 ksi.
22 . A directional drilling system comprising:
a directional drilling tool integrated in a drill string; and
a drill bit coupled to the directional drilling tool, wherein the drill bit comprises:
a casting mandrel portion comprising an amount of steel;
a drill string connection portion comprising an amount of precipitation hardenable steel for coupling the drill bit to the drill string wherein the amount of steel is distinct from the amount of precipitation hardenable steel;
a cutting structure fabricated in a metal matrix composite formed about the casting mandrel portion, wherein the metal matrix composite comprises a reinforcing powder infiltrated with a binder in contact with the casting mandrel portion; and
a bimetallic member comprising the amount of steel and the amount of precipitation hardenable steel metallurgically bonded together before the reinforcing powder is infiltrated with the binder.
23 . The directional drilling system of claim 22 , wherein the directional drilling tool comprises a rotary steerable system.
24 . The directional drilling system of claim 22 , wherein the directional drilling tool comprises a positive displacement motor system.
25 . A method of performing a drilling operation comprising:
coupling a drill bit to a drill string, wherein the drill bit comprises:
a casting mandrel portion comprising an amount of steel;
a drill string connection portion comprising an amount of precipitation hardenable steel for coupling the drill bit to the drill string wherein the amount of steel is distinct from the amount of precipitation hardenable steel;
a cutting structure fabricated in a metal matrix composite formed about the casting mandrel portion, wherein the metal matrix composite comprises a reinforcing powder infiltrated with a binder in contact with the casting mandrel portion; and
a bimetallic member comprising the amount of steel and the amount of precipitation hardenable steel metallurgically bonded together before the reinforcing powder is infiltrated with the binder; and
operating the drill string with the drill bit in a downhole environment to perform the drilling operation.
26 . The method of claim 25 , wherein the drill string further comprises a directional drilling tool coupled to the drill bit, the method further comprising directionally controlling the drill bit through the directional drilling tool in performance of the drilling operation.
27 . The method of claim 26 , wherein the directional drilling tool comprises a rotary steerable system for controlling the drill bit.
28 . The method of claim 26 , wherein the directional drilling tool comprises a positive displacement motor system for controlling the drill bit.
29 . A method comprising:
obtaining an amount of precipitation hardenable steel;
obtaining an amount of another steel, wherein the amount of another steel is distinct from the amount of precipitation hardenable steel;
metallurgically bonding the amount of precipitation hardenable steel to the amount of the another steel, thereby forming a blank bimetallic member comprising a casting mandrel portion and a drill string connection portion;
storing the blank bimetallic member as one of an inventory comprising a plurality of blank bimetallic members;
retrieving the blank bimetallic member out of the inventory of a plurality of blank bimetallic members;
infiltrating a reinforcing powder with a binder in contact with the casting mandrel portion of the blank bimetallic member to form a metal matrix composite about the casting mandrel portion, after the amount of precipitation hardenable steel is metallurgically bonded to the amount of steel; and
fabricating a cutting structure in the metal matrix composite.